Norbornane diisocyanates



United States Patent 3,492,330 NORBORNANE DHSOCYANATES David J. Trecker and Joseph P. Henry, South Charleston, and John W. Lynn, Charleston, W. Va., assignors to Union Carbide Corporation, a corporation of New York No Drawing. Filed Dec. 9, 1965, Ser, No. 520,298

Int. Cl. C07c 119/04, 87/40; C08g 22/24 US. Cl. 260-453 2 Claims ABSTRACT OF THE DISCLOSURE A class of 2,5- and 2,6-disubstituted norbornanes, e.g., 5 (or 6)-aminomethyl-2-(2-aminoethyl) norbornane and 2-(2-isocyanatoethyl)-5 (or 6) isocyanatomethylnorbornane, are produced by the free radical addition of a functionally substituted alkane to the unsaturated carbon atoms of a bridged-ring olefin. The functionally substituted alkane is free of non-benzenoid carbonto-carbon unsaturation and contains at least one hydrogen atom bonded to a carbon atom which, in turn, is (i) a carbon atom of a functional substituent or (ii) a carbon atom in a position alpha to the functional substituent. The nor bornanes produced have the radical of the functionally substituted alkane bonded to the bridged-rim g olefin moiety by a carbon-to-carbon bond. The products are useful in the manufacture of polymers.

This invention relates to a process for the manufacture of substituted norbornanes and to novel norbornanes made by such process. Most particularly, this invention relates to a relatively inexpensive process for the manufacture of substituted norbornanes, particularly disubstituted norbornanes which heretofore could only be produced uneconomically, if at all, by devious manipulation of known processes.

There has previously been described processes which are limited to the production of specified di-substituted norbornanes. For example, US. Patent 2,666,748 describes the manufacture of 2,5 (or 6)-di(aminomethyl) norbornane by the Diels-Alder reaction of cyclopentadiene with acrylonitrile to form bicyclo[2.2.11-5-heptene-2- carbonitrile, followed by reaction of this Diels-Alder product with hydrogen cyanide in the presence of cobalt tetracarbonyl and triphenylphosphine. There was obtained 2,5 (or 6)-norbornanedicarbonitrile which, upon hydrogenation, is converted to the di(aminomethyl) norbornane described previously. This process is incapable of producing any other di(aminoalkyl)norbornane where the amino nitrogen is bonded directly to a primary carbon atom.

US. Patent 2,956,987 describes the manufacture of 2- aminomethyl-S (or 6)-norbornanecarboxylic acid by the hydroformylation of the same carbonitrile described in US. Patent 2,666,748, followed by oxidation of the resulting aldehyde to produce the corresponding cyanocarboxylio acid, which after hydrogenation, provides the aforementioned aminomethylnorbornane carboxylic acid. The patents process is very specific with respect to the type of substitution attainable on the norbornane ring and is incapable of providing a product where the carboxyl group is bonded directly to a primary carbon atom.

In US. Patent 2,917,490, there is described norbornane- 5 (or 6)-amino-2-carboxylic acid which is produced by the reaction of the carboxylic acid hydrolyzate of the monocarbonitrile employed in the previous two patents with a nitrile, such as hydrogen cyanide, acetonitrile or benzonitrile, in the presence of a strong acid. As a result of this reaction there is obtained the addition of a carboxy- 'ice amido group at the ethylenic unsaturation of the carboxylic acid which, after hydrolysis, results in the aforementioned aminocarboxylic acid. The process of that patent is only capable of producing an aminocarboxylic acid wherein the amino nitrogen, as well as the carboxyl group, are bonded to secondary carbon atoms.

In addition to the above, there is described in US. Patent 3,000,864 the compounds 5(or 6)-hydroxynorbornane-Z-carboxylic acid by a process which is the same as that described in US. Patent 2,917,490, except that instead of cyanide addition, a carboxylic acid is employed, followed by hydrolysis resulting in hydroxy substitution. Such a process is incapable of producing substituents bonded to norbornane which are directly attached to primary carbon atoms.

There is described in US. Patent 2,972,602, norbormane-2,5 (or 6)-dicarboxylic acids which are produced by the hydroformylation of the aforementioned carbonitrile, described above, resulting in the formaldehyde-substituted carbonitrile which, after oxidation, is converted to the monocarboxy substituted norbornane carbonitrile and after hydrolysis is further converted to the di-carboxy substituted norbornane. This patent is limited also insofar as it is only capable of producing substituted norbornanes wherein the substituents are bonded to secondary carbon atoms.

US. Patent 3,143,570 describes another process for making the diamine described in US. Patent 2,666,748. The process employed in U.S. Patent 3,143,570 involves the aforementioned hydroformylation technique of the cyanonorbornane followed by reaction of the aldehyde with excess ammonia to form the Schiffs base. The resulting product is hydrogenated in the presence of ammonia to form the diamine.

The process of this invention, in addition to its inherent novelty, is uniquely different from the above art because it is capable of providing multi-substituted bridged-ring compounds, such as di-substituted norbornanes, wherein each substituent is bonded to a carbon atom at least two carbon atoms removed from the other substituent, and at least one of the substituents is in the exo configuration thereby minimizing the extent of intramolecular reaction when the bridge-ring compounds are utilized in polymerization reactions for which they are uniquely equipped. In addition, the process of this invention produces polysubstituted bridge-ring compounds unattainable by prior art processes.

The process of this invention involves the free radical addition of a functionally substituted alkane on a bridgedring olefin. The free radical adddition is effected by intermixture of the olefin in the presence of the substituted alkane and a free radical initiator.

The bridged-ring olefins which may be treated in accordance with the process of this invention possess at least one ethylenic unsaturation and include those characterized by the formula.

wherein Z may be one of wherein x, y, z, q and p are one of the integer and 1, provided that z is 0 when y is 1 and y is 0 when 2 is 1, two of the Rs, R"s, R"s, R""s, R s, R s, R s, and R s, above, when bonded to adjacent ring carbon atoms may be interconnected valence bonds to form ethylenic unsaturation in the ring and one or more of them may be one of hydrogen, monovalent organic radicals and monovalent inorganic sulfur or carbonyl containing radicals, such as: lower alkyl (i.e., of from 1 to about 4 carbon atoms); phenyl, alkylphenyl wherein the alkyl has from 1 to about 6 carbon atoms; carboxyphenyl; hydroxyphenyl; halophenyl (e.g., chloro, iodo, bromo, fiuorophenyl); aminophenyl; cyanophenyl; isocyanatophenyl; carbamoylphenyl; alkoxyphenyl; cyano, hydroxy; hydroxyalkyl of from 1 to about 8 carbon atoms; cyanoalkyl of from 1 to about 9 carbon atoms; amino; aminoalkyl of from 1 to about 8 carbon atoms; carboxy; carboxyalkyl of from 1 to about 9 carbon atoms; halo (e.g., chloro, bromo, iodo and fluoro); haloalkyls of from 1 to about 8 carbon atoms and the halo radicals are those described above; carbohydrocarbyloxy (i.e.,

wherein R is an alkyl group of from 1 to about 8 carbon atoms or phenyl); allroxy of from 1 to about 8 carbon atoms, alkoxyalkoxy of from 3 to about 8 carbon atoms; alkoxy (polyalkyleneoxy) of from about to about 1,200 carbon atoms; hydroxyalkoxyalkoxy of from 3 to about 8 carbon atoms; hydroxyalkoxy of from 2 to about 8 carbon atoms; hydroxyalkoxy(polyalkyleneoxy) of from about 5 to about 1,200 carbon atoms; phenyloxy; phenyloxyalkoxy of from 8 to about 10 carbon atoms; phenyloxy (polyalkyleneoxy) of from 10 to about 1,000 carbon atoms; halophenyloxy wherein the halo subare defined above; hydroxyphenyloxy; carboxyphenyloxy; alkoxyphenyloxy, wherein the alkoxy moiety has from 1 to about 6 carbon atoms; aminophenyloxy, cyanophenyloxy; alkylphenyloxy wherein the alkyl moiety has from 1 to about 8 carbon atoms; carbamoylphenyloxy; alkanoyl a 0 H R"G wherein R" is an alkyl group of from 1 to about 6 carbon atoms); phenylcarbonyl; benzylcarbonyl; alkanoyloxy wherein the alkanoyl group contains from 1 to about 18 carbon atoms; phenoyloxy, benzoyloxy; alkylthio; phenylthio; benzylthio; mercapto; sulfo; sulfamido; 1,2- epoxyalkyl containing from 2 to about 8 carbon atoms; part of carboanhydrides wherein two of R and R to R each joined to adjacent carbon atoms of the bridged-ring olefin, are divalent carbonyl radicals; part of dialkyleneoxide wherein each alkylene has from 1 to about 10 carbon atoms and are joined at one free valence to oxy and the free valences of the radical are directly bonded to adjacent carbon atoms of the bridged-ring olefin; part of dialkylene sulfide, dialkylene sulfoxide and dialkylene sulfone wherein each alkylene has from 1 to about 10 carbon atoms and the free valences of the radical are directly bonded to adjacent carbon atoms of the bridgedring olefin; part of oxydicarbonyl wherein its free valences are directly joined to adjacent carbon atoms of the bridged-ring olefin; part of alkylene of from 2 to about 8 carbon atoms where its free valences are bonded to adjacent carbon atoms of the bridged-ring olefin; part of alkenylene of from 2 to about 8 carbon atoms where its free valences are bonded to adjacent carbon atoms of the bridged-ring olefin, carboxamide; alkamido of from 1 to about 9 carbon atoms; phenylamido; benzylamido; chloroforrnyl; part of imidodicarbonyl where the free valences are bonded to adjacent carbon atoms of the bridged-ring olefin; keto; part of alkylenone of from 1 to about 8 carbon atoms where the free valences are bonded to adjacent carbon atoms of the bridged-ring olefin; part of dicarbonyl alkylene of from 3 and 4 carbon atoms where the free valences are bonded to adjacent carbon atoms of the bridged-ring olefin; part of dioxyalkylene of from 2 to about 8 carbon atoms where each oxygen is directly bonded to the same carbon atom of the bridgedring olefin; thio; part of methylene where the carbon is double bonded to a carbon atom of the bridged-ring olefin; part of alkylmethylene, dialkylmethylene, alkylphenylmethylene, benzylalkylmethylene (where the alkyl groups have from 1 to about 8 carbon atoms), phenylmethylene, diphenylmethylene, benzylmethylene, diben zylmethylene and phenylbenzylmethylene wherein the methylene moiety is double bonded to a carbon atom of the bridged-ring olefin; part of isonitroso Where the nitrogen is double bonded to a carbon atom of the bridgedring olefin; dialkoxyalkyl of from 3 to about 9 carbon atoms, alkylene-dioxylalkyl of from 3 to about 7 carbon atoms; part of oxycarbonyl wherein its free valences are directly bonded to adjacent carbon atoms of the bridgedring olefin; part of dialkyleneoxycarbonyl of from 3 to about 8 carbon atoms where its free valences are directly bonded to adjacent carbon atoms of the bridged-ring olefin; divalent alkylenecarbonyloxy and carbonyloxyalkylone where the alkylene group has from 1 to about 6 carbon atoms and the free valences are joined to adjacent carbon atoms of the bridged-ring olefin; part of divalent oxy where each tree valence is joined to adjacent carbon atoms of the bridged-ring olefin; glycidyloxy; and the like. Illustrative examples of radicals representing one or more of the Rs, R"s, R"s, R's, R s, R s, R s, and R s include: methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec.-butyl, t-butyl; 4-methylphenyl, 4 ethylphenyl,

phenyl, and the like; 4-carboxyphenyl, 3,5 dicarboxyphenyl, and the like; 4-hydroxyphenyl, 3,5 dihydroxyphenyl, 3,4,5-trihydroxyphenyl, and the like; 4-chlorophenyl, 4-bromophenyl, 3-fluorophenyl, 2,4 dichlorophenyl, 4-iodophenyl, 2,3,4,5,6-pentachlorophenyl, and the like; 4-aminophenyl, 3,5 diminophenyl, 4 aminomethylphenyl, 4-gamma amino propylphenyl, and the like; 4-cyanophenyl, 3,5 dicyanophenyl, 2,4-dicyanophenyl, and the like; 2,5-diisocyanato 4 methylphenyl, 4 isocyanatophenyl, and the like; 4 carbamoylphenyl, 2,5 dicarbamoyl 4 methylphenyl, and the like; 4 methoxyphenyl, 2,4 diethoxyphenyl, 4 methoxy 3,5- diethoxyphenyl, and the like; 2 hydroxyethyl, hydroxymethyl, 4 hydroxybutyl, 1,2 dihydroxyethyl, 6 hydroxy 2 ethylhexyl, and the like; cyanomethyl, 2-cyanoethyl, cyanohexyl, and the like; aminomethyl, 3- aminopropyl, 8 aminooctyl, and the like; 2 carboxythe like; 4 aminophenyl, 3,5 diaminophenyl, 4 aminoethyl, 4-carboxypentyl, and the like; chloromethyl, trichloromethyl, perchloropropyl, perfiuorobutyl, 2-chl0ro- 1,2-tetrafiuoroethyl, and the like; carboethoxy, carbomethoxy, carbocyclohexyloxy, carbophenyloxy, and the like; methoxy, ethoxy, isopropoxy, n-propoxy, hexoxy, and the like; methoxyethoxy, methoxypropoxy, methoxyisopropoxy, ethoxybutoxy, and the like;

CHacHzO CHzCHO CHao oHzcHzo I and the like; hydroxyethoxy, hydroxyisopropoxy, hydroxy n propoxy, and the like; hydroxyethoxyethoxy,

H: 2 to 400 and the like; 4-chlorophenoxy, 4-bromophenoxy, 3,5-diiodophenoxy, and the like; 4-hydroxyphenoxy, 3,,5-dihydroxyphenoxy, 4-hydroxymethylphenoxy, and the like; 4-carboxyphenoxy, 2,4-dicarboxyphenoxy, and the like; 4-methoxyphenoxy, 2,4-di-n-butoxyphenoxy, and the like; 4-aminophenoxy, 4-aminomethylphenoxy, and the like; 4-cyanophenoxy, and the like; 4-methylphenoxy, 2,3,4,5,6- pentamethylphenoxy, 4-n-octylphenoxy, and the like; 4- carbamoylphenoxy, and the like; acetyl, propionoyl, benzoyl, phenylacetyl, and the like; acetyloxy, propionoylloxy, benzoyloxy, phenylacetyloxy, and the like, methylthio, n-hexylthio, and the like; ethylsulfamido, and the like; 1,2-epoxyethyl, 7,8-epoxy-n-octyl, 3,4-epoxy-n-hexyl, and the like; dimethyleneoxide, diethyleneoxide, methylene ethyleneoxide, and the like; dimethylene sulfide, diethylene sulfoxide, methylene ethylene sulfone, and the like; ethylene, tetramethylene, and the like; propenylene, 3-n-hexylene, and the like; acetamido, butyrarnido, and the like; trimethylen-Z-one, pentamethylen-Z-one, and the like; tetramethylen-1,4-dione, heXamethylen-l,6-dione and the like; dioxyethylene, dioxypropylene, and the like; methylmethylene, dimethylmethylene, methylethyl methylene, phenylmethylene, methylphenyl methylene, diphenylmethylene, methylbenzyl methylene, dibenzylmethylene, and the like; dimethoxyrnethyl, diethoxymethyl, dibutoxymethyl, 1,1-dimethoxyethyl, and the like; 1,2-ethylenedioxymethyl, 1,2-ethylenedioxy-1-ethyl, and the like; di- (methylene)oxycarbonyl, methyleneoxycarbonyl, methylenecarbonyloxy, di(ethylene)oxycarbonyl, and the like.

The aforementioned bridge-ring compounds are obtained easily by classical reactions such as by a Diels- Alder reaction between cyclopentadiene or substituted and the like; phenyloxyethoxy, the like;

cyclopentadiene and an ethylenically unsaturated compound which may or may not bear the aforementioned substituents. The following table illustrates the type of products produced. It must be borne in mind that the following is not intended to restrict the scope and number of bridged-ring compounds usable in the practice of this invention.

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mmsurcuu Barman-Rim cycrorenrmrsm: uusmmman COMPOUND compounns TABLEContinued CH2 D it I c11 C126 2 01 Q) (pan.

wasps E o ca weeps;

COZCH:

o (3 UK? As mentioned previously, this invention involves the addition of functionally substituted alkanes in the bridgedring olefin at the unsaturation thereof. The term functionally substituted alkanes as employed herein encompasses free of non-benzenoid carbon to carbon unsaturation and which contain at least one hydrogen atom bonded to a carbon atom which in turn is a carbon atom of a functional substituent or a carbon atom in a position alpha to a functional substituent. Illustrative of the term functional substituent or functionally substituted, as employed herein, are the following: hydroxyl cyano, carboxy, hydrocarbyloxycarbyl, amino, oxy, dicarboanhydn'de, formamido, carboxamido, phenyl, substituted phen yl (wherein the substituents are alkyl (1 to about 20 carbon atoms) halo (as described above), hydroxy, carboxy, cyano, amino, alkoxy (1 to about 4 carbon atoms)), carbamoyl, and the like.

Apart from the functional substituents, these compounds are typically composed of carbon and hydrogen, and in many cases, oxygen also. Illustrative functionally substituted alkanes suitable in the practice of this invention include, by way of example only, the following: alkyl and alkylene alcohols, such as methanol, ethanol, isopropyl alcohol, isobutyl alcohol, cyclohexanol benzyl alcohol, benzyhydryl alcohol, ethylene glycol, 1,2-propylene glycol, 1,4-butane diol, glycerol, and the like; cyanides, such as methyl cyanide, ethyl cyanide, isopropyl cyanide, ben- Zyl cyanide, cyclohexyl cyanide, malononitrile, cyanohydrin, and the like; carboxylic acids, such as acetic acid, propionic acid, butyric acid, 1,4-cyclohexanedicarboxylic acid, isobutyric acid, phenylacetic acid, cyclopentylcarboxylic acid, malonic acid, succinic acid, glutamic acid, adipic acid, stearic acid, lactic acid, 1,4-bis(carboxypropyl)ben zene, glycine, and the like; carboxylic esters, such as ethyl acetate, methyl isobutyrate, methyl acetate, isopropyl isobutyrate, ethyl phenylacetate, methyl cyclohexylcarboxylate, dimethylmalonate, dineopentyladipate, diethyl succinate, and the like; amines, such as methyl amine, trimethylamine, diethylamine, cyclohexylamine, benzylamine, nbutylamine, ethylenediamine, diethylenetriamine, morpholine, hexamethylenediamine, ethanolamine, diethanolamine, piperazine, methylolamine, N,N,N"-trimethylmelamine, N,N,N-trimethy1olmelamine, and the like; epoxides and ethers such as diethyl ether, dimethyl ether, ethylene oxide, propylene oxide, 1,4-dioxane, epichlorohydrin, tetrahydrofuran, phenyl isopropyl ether, phenyl methyl ether, dimethyl ether of ethylene glycol, dimethyl ether of dipropylene glycol, hydroxy-terminated polyalkylene oxides (e.g., polyethylene oxide), and the like; anhydrides such as acetic anhydride, diisobutyric anhydride, succinic anhydride, benzoic acetic anhydride, and the like; formamides, such as formamide, methyl formamide, diethyl formamide, dimethyl formamide, phenyl formamide; formic acid and derivatives, such as methyl formate and phenyl formate; amides, such as acetamide, n-propionamide, n-butyramide, isopropionamide, isobutyramide, adipamide, succinamide, N-methylacetamide, N,N-diethylacetamide, ethylene bis-acetamide, N,N-diethyladipamide, ethylene bis(isobutyramide), and the like; phenyl derivatives, such as methylbenzene, ethylbenzene, isopropylbenzene, n-octylbenzene, n-laurylbenzene, bis (phenyl)- methane, bis(4-phenyl)-l-ethane, 1,4-dimethylbenzene, l, 3,5-trimethylbcnzene, 4-carboxytoluene, 4 chlorotoluene, 2,4-dichlorotoluene, 3-trifluoromethylcumene, 4 methylphenol, 5-methylpyrogallol, 4-methylbenzoic acid, S-methylphthalic acid, 2-methylterephthalic acid, 4-cyanotoluene, 3-methylaniline, 4-methoxytoluene, 3-n-butoxycumene, 2- methylolphenol, 3-carbamoyltoluene, N-methylcarbarnoyltoluene, N-phenylcarbamoyltoluene, N-phenyl-N-methylcarbamoyltoluene, 2,4-toluenediisocyanate, and 2,6-toluenediisocyanate (and mixtures of toluene diisocyanates).

It is to be appreciated from the above that the term functionally substituted alkane (or alkane for brevity) is not intended to be construed as simple alkane bearing a functional substituent, but rather is intended to mean herein to be a functionally substituted organic compound free of ethylenic and acetylenic unsaturation and containing a carbon atom having a hydrogen atom directly bonded thereto which carbon atoms is in one of the following positions: the position alpha to the functional substituent where the substituent is free of such a carbon atom and a position part of the functional substituent. The remainder of the organic compound may contain any other combination of atoms. The organic compounds may contain 1, 2, 3, 4, and more functional substituents though preferably not more than 2 such substituents.

The aforementioned reaction occurs by Way of free radical addition by intermixing at least one of the functionally substituted alkanes with at least one of the bridged-ring olefins in the presence of a free radical initiator, such as the conventional free radical addition catalysts so well known in the art. The general classes of free radical initiators include peroxides, azo compounds, peresters, peracids, heat and the like.

Illustrative of suitable initiators include the following: peroxide compounds such as tertiary butyl hydroperoxide, di-tert.-butyl peroxide, di-tert.-amyl peroxide, lauroyl peroxide, benzoyl peroxide, cumene hydroperoxide, dicumyl peroxide, hydrogen peroxide, tert.-amyl hydroperoxide, ter't.-hexyl hydroperoxide, diacetyl peroxide, as well as many others; azo compounds such as azo-bisisobutyroni trile, azo-bisisoamylnitrile, azo-bisisohexylnitrile, azo-bis- Z-ethyl butyronitrile, azo-bis-2-methyl-3-phenyl propionitrile, azo-bis-2-n-propy1 amyl nitrile; peresters such as tertiary butyl peracetate, cyclohexyl peracetate, neo-pentyl peracetate, peracids such as peracetic acid, perpropionic acid, perisobutyric acid and the like.

Broadly, the function of the free radical initiator is to provide energy for removal of a hydrogen atom from the functionally substituted alkanes described above. The energy may be in the form of radical fragments from the initiator (as is the case with the peroxides, peracids, peresters and the azo compound) or be in the form of thermal energy.

The free radical addition reaction may be effected in liquid or vapor phase. The liquid phase reaction may be effected as a heterogeneous or homogeneous liquid phase mixture of the component involved in the addition reaction. Essentially all of the functionally substituted alkanes described above are liquid at the temperature of the addition reaction and therefore can be utilized as the liquid body in which the bridged-ring olefin and the initiator is dispersed. The manner of dispersion i.e., whether homogeneous or heterogeneous, depends on the solvating action of the functionally substituted alkane towards the bridged-ring olefin employed, or the solvating action of the bridged-ring olefin employed toward the functionally substituted alkane. Usually, an excess of one of the functionally substituted alkane and the selected bridged-ring olefin is employed when one of them is chosen to serve as the solvating or dispersing medium.

However, other compounds which are liquid at the addition reactive temperature may be optionally employed as a solvent for one or both of the prime reagents (i.e., the alkane and the bridged-ring olefins) or as a liquid dispersant for both. Illustrative of such compounds include, by way of example only, benzene, chlorobenzene, 1,4-dichlorobenzene, 1,2-dichlorobenzene, 1,3-dichlorobenzene, nitrobenzene, 1,2-dinitrobenzene, diphenylether, bis(4-chloropheny1)ether, 1,2- and 1,6-dichloronaphthalene, and the like. The selection of such solvating or dispersing liquids is not critical except that they should be essentially inert to the free radical addition reaction and not cause an unwanted amount of reaction by-products.

In the preferred operation of this process, an excess of the functionally substituted alkane over the stoichiometry of the reaction is employed to provide the liquid conditions of the reaction. In the most preferred embodiment, the reaction is carried out as a homogeneous liquid phase.

The process may also be carried out in the vapor phase where the alkane and bridged-ring olefin is intermixed as gases in an environment containing the free radical initiator. For example, a stream comprising an admixture of alkane and the bridged-ring olefin can be passed through a bed of zeolitic molecular sieves having adsorbed therein one of the aforementioned peroxides, peracids, peresters and 2120 compounds. Particularly preferred, is a zeolitic molecular sieve having di-tert.-butyl peroxide or tert.-butyl hydroperoxide adsorbed therein. At the temperature of reaction, the initiator is desorbed from the sieve to catalyze the reaction or the reactants are absorbed into the sieve where catalysis takes place. Usually both occurs during the reaction.

A preferred manner of carrying out the addition reaction involves adding the bridged-ring olefin and the initiator in the initiator in incremental portions to an excess of the functionally substituted alkane heated at the reaction temperature. The resulting addition product is separable from the reaction system by conventional procedures such as distillation, crystallization, solvent extrac tion, decantation, and the like. Distillation is the procedure most often employed.

The addition reaction proceeds at a rate dependent upon the reactants, the catalysts, the concentrations of the reaction components, the solvent, the temperature and the like considerations. Usually, the reaction can vary over seconds to hours depending upon the above points of consideration typically controlling reactions.

The reaction may proceed over a wide temperature range, but, however, the temperature of the reaction must be sufficiently high enough to cause the initiator to provide the energy for removal of a hydrogen atom from the functionally substituted alkane. With respect to the compounds which are free radical initiators, the temperature should be sufficiently high to cause their decomposition into free radical fragments. Depending upon the free radical initiator employed, the temperature of the reaction may range from about C. up to about 250 C., preferably from about 30 C. to about 200 C. In the usual case, the temperature employed is between about 80 C. and about 180 C., inclusive, and more preferably, between about 110 C. and about 160 C., inclusive. The most preferred operating temperature ranges from the standpoint of rate and yields is between about C. and about C., inclusive.

The proportion of the functionally substituted alkane to the bridged-ring olefin may vary considerably, but for better yields of reaction product it is desirable to employ a molar ratio of the functionally substituted alkane to the bridged-ring olefin of at least about 0.1. This molar ratio may be as large as 500, or more. Preferably, the molar ratio of the alkane to the bridged-ring olefin is between about 0.5 and about 500, inclusive, and, most desirably, between about 2 and about 300, inclusive. In the most preferred embodiment, where optimum yields are most often attainable, the molar ratio is typically between about 5 to about 200.

The amount of free radical initiator necessary is that catalytically effective amount which causes the free radical addition reaction to proceed. In the case of the free radical initiating compounds, the usual catalytic quantities are employable. Typical catalytic quantities of these compounds may range from about 0.01 mole percent to equal molar quantities based on the molar amount of the bridged-ring olefin undergoing reaction. Preferably, there is employed from about 5 to about 50 mole percent of the compound, based on the molar amount of the bridged-ring olefin undergoing reaction, and the most desirable amount of the compound is from about 20 to about 40 mole percent, based on the moles of the bridgedring olefin undergoing reaction.

The process, when carried out in liquid phase, may be under any atmosphere, though preferably under an inert atmosphere such as nitrogen, carbon dioxide, argon, helium, and the like. In a vapor state reaction, the atmosphere should be inert. This may be accomplished by maintaining the reactant vapors as the total atmosphere or by feeding an inert gas or gases, such as the above inert gases, to the reaction zone.

The pressure at which the reaction proceeds is not critical. However, when the alkane is gaseous at the reaction temperature, it is preferable to employ superatmospheric pressure conditions. Subatmospheric or atmospheric pressures may be employed instead, but are desirably utilized when all of the reactants are liquid at the operating temperature. In vapor phase reactions, pressures ranging from subatmospheric to superatmospheric may be employed.

Typical of the functionally substituted bridged-ring compounds obtained by the process of this invention and the manner by which they are obtained are illustrated by the following:

01. o1 I} N R\ Peroxide N 4;

cu-cu A 02 5 (0 6)-Cyanonorbornane -(4 .e -d1subatizuted)- acetonitz'tle 11 or: m/mr n 3 I 5 3 1 2 2 f i-PrOH H N-ca e 5(er 6)-km1mmesa 1-2-{1,1- d lsubst. ibuted-Z-amtnoethyl} norboir nane R 5 (or 6) -Isocyanatome thy]. -2

(1 l-disubstttuted -2-1.aoeyanatoethyl) norbor'nane 01 01. e]. I Peroxide I-6N /CH-CN NC-(E R 02 A oz 5,ll(ot l2)-Di(cyano disubstituced methy1)gentacyc1o[8.2.l. l .0 .0 ldodecane 11 1 iii/NR 01 1.101 CH NH I- 2 5,110): 12)-ui(aL,e -dtsubsci- :uted B-zmincmethyDgex-rtaeyclo [3.2.1.1 .o .o ldodecane wherein R is an alkyl group of from 1 to about 8 carbon atoms or phenyl); alkoXy of from 1 to about 8 carbon atoms, alkoxyalkoxy of from 3 to about 8 carbon atoms; alkoxy(polyalkyleneoxy) of from about 5 to about 1,200 carbon atoms; hydroxyalkoxyalkoxy of from 3 to about 8 carbon atoms; hydroxyalkoxy of from 2 to 8 carbon atoms; hydroxyalkoxy(polyalkyleneoxy) of from about 5 to about 1,200 carbon atoms; phenyloxy; phenyloxyalkoXy of from 8 to carbon atoms; phenyloxy(polyalkyleneoxy) of from 10 to about 1000 carbon atoms; halophenyloxy wherein the halo substitutents are described above; hydroxyphenyloxy; carboxyphenyloxy; alkoxyphenyloxy wherein the alkoxy moiety has from 1 to about 6 carbon atoms; aminophenyloxy; cyanophenyloxy; alkylphenyloxy wherein the alkyl moiety has from 1 to about 8 carbon atoms; carbamoylphenyloxy; alkanoyl (e.g.,

o HL wherein R" is an alkyl group of from 1 to about 6 carbon atoms); phenylcarbonyl; benzylcarbonyl; alkanoyloxy wherein the alkanoyl group contains from 1 to about 18 carbon atoms; phenoyloxy; benzoyloxy; alkylthio; phenylthio; benzylthio; mercapto; sulfo; sulfamido; 1,2-epoxyalkyl containing from 2 to about 8 carbon atoms.

Particularly desirable substituted norbornane compounds are produced in the following manner:

Peroxide CH CO E Q) W [B 2 Peroxide CH C CH CN 2 N i-PrOH CHZCRZNHZ N-Ca cu cu uco coc1 ocN-cu CHZCN H20 NC cu 0u CH30 C wcu co cu [)j/co cu cu on Pero'xide uocu a n T@ co cu cu HOG-[24$ A cu ou cu on" on cu Peroxide uc-ca 2 m/us on 011 NC u R H z a n-cu i-Prou 2 CH on H 0 cu co cu 2 uocu an on uocu Z 2 3 2 {U 3 H2504 a CH OH Peroxide TSP is the abbreviation for di-terc.bucyl petoxide(a1so 'called terc.-bucyl peroxide) A unique feature of the novel process herein is its capability of producing poly-substituted norbornane wherein at least one of the substituents is in the exo configuration. This means that the poly-substituted norbornanes produced by the process of this invention readily enter into polymerization reactions with minimization of internal reaction. Moreover, the process of this invention can be employed to make poly-substituted (particularly di-substituted) norbornane unattainable by prior art processes.

A particularly preferred embodiment of this invention involves the production by the process of this invention of 27 2,5 and/or 2,6 di-substituted norbornanes characterized by the following formula: II

wherein X may be one of CR R CN, CR R OH, CR R CR R NHR CR R COR CR R N C O g nr C v g vr and CR R NR COR R R R R R and R" may each be one of amino, halogen (such as Cl, F, and Br), hydrogen and carbon bonded monovalent organic radicals such as alkyl of from 1 to about 18 carbon atoms, phenyl, benzyl, cycloalkyl of from about 5 to about 8 carbon atoms, carboxylalkyl of from 1 to about 1 carbon atoms, alkylcarboxylalkyl of from 2 to about 20 carbon atoms, cyanoalkyl of from 1 to about carbon atoms, carboxyphenyl, carboxyphenylalkyl, wherein the alkyl radical contains from 1 to about 6 carbon atoms, aminoalkyl of from 2 to about 10 carbon atoms, carbamoylphenyl, phenylcarbamoylphenyl, halophenylcarbamoylphenyl, 7 naphthylcarbamoylphenyl, carbamoylalkyl of from 1 to about 9 carbon atoms, phenyl carbamoyl alkyl wherein the alkyl radical has from 1 to about 8 carbon atoms, isocyanatoalkyl of from 2 to about 7 carbon atoms, isocyanatomethylphenyl, isocyanatophenyl, isocyanatophenylmethylphenyl, hydroxyalkyl of from about 1 to 10 carbon atoms, hydroxyalkoxyalkyl of from about 3 to 5 carbon atoms, hydroxyphenyl, hydroxyphenylalkyl wherein the alkyl radical contains from 1 to about 5 carbon atoms, hydroxylpolyalkyleneoxyalkyl containing from 2 to about alkyleneoxy radicals and the alkyl radical contains from I to about 4 carbon atoms, alkoxyalkyl containing from about 2 to about 11 carbon atoms, alkoxypolyalkyleneoxyalkyl containing from 2 to about 20 alkyleneoxy radicals and the alkyl radicals contain from 1 to about 4 carbon atoms, vicinalepoxyalkyl wherein the alkyl radical contains from 2 to about 8 carbon atoms, haloalkyl wherein the alkyl contains from 1 to about 8 carbon atoms and the halo radical is at least one of chloro, iodo, bromo, and fluoro, halo substituted phenyl wherein the halo substituent(s) is one of chloro, iodo, bromo, and fluoro and from 1 to 5 halo substituents are substituted on said phenyl radical, haloalkyl phenyl wherein the halo is one of those described above and the alkyl radical contains from 1 to about 4 carbon atoms, and the like organo radicals; and Y may be one of X with the exception of CR R OH, and CN, OH, CR R NHR COR and -N=C-=O; wherein R may be one of chlorine, hydroxyl, alkoxy of from 1 to about 18 carbon atoms, phenyloxy, benzyloxy, cycloalkyloxy of from about 5 to about 8 carbon atoms, alkali metal oxide (such as lithium, sodium, potassium, cesium, rubidium), NHJ, quaternary ammonium oxide (+NR O, wherein R is alkyl of from 1 to about 4 carbon atoms, phenyl and benzyl), and the like radicals; and

n is one of the integers 1 and 2 The compounds encompassed by Formula II are formed by the Diels-Alder reaction between cyclopentadiene and a functionally substituted ethylenically unsaturated compound to produce Z-functionally substituted-S-norbornene by adding an aforedefined functionally substituted alkane to the functionally substituted norbornane by the above described process.

To illustrate, cyclopentadiene, i.e.,

can be reacted with a functionally substituted ethylenically unsaturated organic compound, such as CHzCN CH2=CHCHGN, CHz OHHCN, CH2=CIICHzCOOH 2H5 CH CHCHCOOH, CHZZCHCHBI'COOH, CHz CHCHCOOH CH CHz=CHGHCOOH, CH2=CHCFzCOOH, CHz=CHJ-COOH CH2 HCCOOH, CH =CHCH OH CH2=CHCHz@0H, CH2=CHCHCH2OH CHZZCHCHCHZOH, CH2=GHCHCOOEL CH2=CHCHCOOH OOH Hz-CHz (30 OH CH2- CH CHz=CHGH-CH CH CHCHC O O H, C1-I2=OHC 0 0 CH OHZ=GHCO 0 C 11 (hexylacrylate) HgCHgCN (phenyl acrylate) CHZ=CHO 0 ONH OHZ=CHOHZC O ONa GHQ-CH2 CH CHz 1 CH2=CHCH2COOCH CH2=CHCHCOOH CH =CHOHC O O CQHE COO C lGH'zl (decyl ethyl-Z-vinyl malonate) and the like. I 7 5 CHZ=CHCHCO 0 CH K3 coo CH2=CHCHC O O CH The aminoalkylnorbornane compounds may be produced by the hydrogenating a mono or polycyanoalkyl substituted norbornane. The mono or polyisocyanates can be produced by phosgenating mono or poly aminoalkyl substituted norbornane and then dehydrohalogenated the resulting chloroformate. Hydrolysis of the chloroformate results in a carbamic acid derivative. The above are well known procedures and are conventionally employed herein.

Illustrative functionally substituted alkanes in addition to those described previously, which are suitable for addition reaction with the norbornenes to produce the compounds of Formula II include, for example, the followmg:

HOCHgCl-LCN, CH3CII1OCH2CI12CN, CHZlOCH-QCIIBOCHgCHZCN NC CHgCHgCN, NC CH CH CHQCHQCN, HQNCHjCHgCOOH CILCHgOOCCHgC OOCHzCHa-QCILCOOH HOOCCHZCHjCOOH, HZNCHQCHECHECOOH The novel disubstituted norbornane compounds defined by Formula II find a variety of uses and are particularly suitable in the manufacture of polymers which in turn can be used in the manufacture of fibers, films, coatings, molded objects, castings, and plasticizers. The polymers that are produced from the novel norbornanes depicted by Formula II are typically those which involve a condensation reaction or an addition reaction of the urethane type, viz, the reaction of an isocyanate and an active hydrogen compound, as determined according to the Zerewitinoff method described in the Journal of the American Chemical Society, vol. 48, page 3181 (I927). The polymers possess the recurring unit,

i.e., the divalent norbornylene radical, within its internal structure.

The functional substituents on the norbornane ring determine the type of polymer which is formed. For example, if the functional substituents bear isocyanato radicals, the novel substituted norbornanes may be employed in the manufacture of polyurethanes, polyureas, mixtures of polyurethanes and polyureas, and l,1-addition polyamides by reaction with itself or other isocyanates. The novel norbornanes bearing at least one carboxyl group may be employed in the manufacture of polyester compositions, polyamide compositions, as hardeners in the curing of epoxy compositions, and the like. The novel norbornane compounds encompassed by Formula II which contain at least one amido group, may be employed as a reactant to make polyamides, polyureas, act as a conventional amine hardener for epoxy resins, as reactant with alkylene oxides to form a polyalkylene amide adduct, as a reactant with aldehydes to form aminealdehyde resins, and the like. The novel norbornane compounds which contain at least one hydroxyl group can be employed to manufacture polyesters, polycarbonates, alkylene oxide adducts, polyurethanes, and the like. The novel norbornane compounds within Formula II which bear at least one oxirane group may be employed in the formation of epoxy resins by acid or alkaline hydrolysis or by reaction with conventional epoxy hardeners, or may be employed as a precursor for hydroxyl-containing monomers by simple hydrolysis of the oxirane group.

The novel carbamates esters encompassed by Formula II (including the carbamic acid derivatives) may be employed in a manner similar to the carboxy derivatives described above to form polyureas, polyurethanes, and the like.

Thus, the divalent norbornane radical is joined through a linkage to other segments of the polymer strccture. Such linkages include, by way of example, the ester linkage, that is, a linkage formed by joiing the free valences of a carbonyloxy radical to carbon atoms; a carbonamide radical (CONH) where the free valences thereof are joined to carbon atoms; oxy radical, that is, an ether oxygen group where the divalence of the oxygen is directly joined to carbon atoms; urethane linkages, i.e., NHCO, where the free valences thereof are joined directly to carbon atoms; urea linkages, i.e., NHCONH, where the free valences are directly joined to carbon atoms.

Such linkages are separated typically from the norbornane radical by at least one carbon atom which is directly joined to the norbornylene radical III.

The following discussion of specific illustrations of the types of polymers producible from the 2,5 and/or 2-6-norbornanes of Formula II is regarded only as illustrative of the products embraced by this invention and is not intended to limit the scope of this invention.

The diisocyanates of Formula II, illustrated by may be reacted with active hydrogen containing compounds such as a polyol such as those of the following formula:

wherein A may be a radical such as and O an integerz of at least 1 Wis an' integer equal to' the free valence'ofcthe' radical A minusthei valne of 1), each R R 'and'R "may be oneiof hydrogen, an alkyl group of'from-l 'tb 18 carbon atoms, preferably from 1 'to 4 carbon atoms, 'cyc'loalkyl 'of-frorn'i- 5 to 7' carbon ato'ms, or-a-n aryl groupyy is an integer-of from 1' to 10; m is an integer of from to 8; g can be an integer of from 1 to 1G; 11 be an'inte-ger of from l to8; x isone of the image s 0' to'lft' is an'inte'ger offrom-2 150-4; 0 is a numb r hayingan average value ofiat least 2; M: is a radical-Which can be'a-lkyljar'alkyl, I

,.0 is one: o f the integeFs O otal; Bishydroigen organ alkyl groupgoisfrom 11 to.4; carbon atoms; L isv B or w e'iii thefree valenceiof is the valence bond of L; d d andg" are each equal to 4 to f is either a v alue oft) to I; and R is methyl when 3 is (land hydrogen Whenf is 1.

Polyols encompassed by the-"above Formula IV include those formed by the addition of alkylene oxides to an iigpolyhyd'roxy" substituted or'g'anioco'mpeundih 'iiihlcilr e'hydroxysubstituents are 'b 'onded tb carbo'n of the organic compound and the initiating polyhydiox'y "s'iibstituted organic compounds. I

The result ofs'uch addition. tormsja hydroxylated alkylene oxide adduct t said hyclroxy substituted organic compound. Thus, various 'l',2 '-alkylehe oxides such as ethylene oxide, l,2-propyl e ne oxide; 1,2-butylene oxide, l,2-hexyl 'ene oxide, l,2-dodecylene oxide, cyclohexyl ethylerie foxidefiand styrene oxide; .or, mixtures thereof, may be polymerized by contact witli a basic or acidic catalyst inthe presence of the initiating polyhydroxy organic compound. The aforementioned 1,2-alkylene oxides may be copolymerized with 1,3- and 1,4-alkylene oxides by acid catalytic polymerization. in the presence of the initiatingfpolyhydroxy organic co mpou nd. Illustrative of various 1,3 and; l,4"-alkyl eiieoxides include 1,3- ppopylene oxide, ,L L-butylene oxide (tetrahydrofuran), li4-pentylene' oxide," 'l=,4-octylene oxide, etc., and 1,4- e'poxy-lphenyl butane, and the like. The 13- and 1,4- alkylene oxides may bereacted above with the initiating hyd'roxyfcompound to form useful polyolis.

' The initiating polyhydr'oxy organiccor'npou'nd include by Way of exam-ple LZ-alkylene glycol, 1,3-alkylene glycol, 1,4-alkylene glycol, "alkylene tetrols, alkylene pento'ls,"alkylene hexols, polyalkylene glycols, etc. Illustrative of these materials include, ethylene glycol, andlii-dihydroiiypropane, 1,2-, 1,3-, 1,4-dihydroxypentane, 1,2 l,3-, 1,4-dihydroxyhexane, 1,2- 1,3 1,4-dihydroxydecane, l, 2-, 1,3 l,4-d ihydroxyoctadeca'ne, and the alpha, omega diols of the above hydrocarbon moieties not indicated as 'such. Polyalkylene glycols" include, 'diethylene glycol, triethylene glycol, tetraethylene glycol, 1,2- and 1,341i1iropylene glycol, l,2- and 1,3-tripropylene glycol, 1,2-, 1,3- and l,4 dibutyle nef"-glycol, 'l,2'-; l-,3- and 1,4-tributylene glycol, etc. Triolswhich may be utilized as the initiating hydrbxy organ-icc'ompou'rld' include, glycerol,- 1,l,l*trifnithylolpropafie;1,2,3 'trihyd'roxybuta'ne, 1-,2;3 tritriols, alkylene c'arboxylic acid-and/ or the corresponding alpha, :org'anolactone, e.g., epsilon caprolactone.

3.2 decane, l,2,4-t rihydroxybutane, l,2,4-trihydroxyhexane, 1,2,6-trihydroxyhexane, 1,2,8-trihydroxydctane, and the like/illustrative of other polyolsz-which are suitable initiators -include 2,5 or' 2,6-bis(hydroxyrnethyl)norbornane, sorbitol, pentaerythrito'l, erythritol, aromatic 'hydroxy compounds of the iorrnulae'r andthe like, and the saturated (non-benzenoid) derivatives thereof; various other carbohydrates such as the monosaccharides and polysaccharides, eg. cellulose; starch; glucosides, such as the lovver alkyl (l to 6 carbon atoms) I gluco sides, e.g., methyl-Darabinoside, methyl- D-xyloside, ethyl-D-xyloside, nbutyl-D-riboside, methyl, ethyl, propyl, butyl, andv 2-ethyl-hexyl-D-glycoside, 2- ethylhexyl-D fructoside, isobutyl-D mannoside, ethyl-D galactosid'e, 'en'zyl-D-g'lycoside and rnethyl-L-rhamrnoside, i suc'rojs'e; glycose l s y s i9 wse; QDI- gulose, D i'do'se, hydroxyethyl cellulose; aniylosqar nylopectin; dextrimand the like.

In making the addition products of epoxy and polyhydroxycompound, the initiator is admixed with the alkyleneoxide in a liquid phase and the basic or, acidic catalyst is dispersed throughout this phase. Suitable basic catalysts include, alkalimetal hydroxides such as sodiurn hydroxide. and, potassium hydroxide. ,Desirable acidic catalysts include Lewis acids such as boron .trifluoride, aluminum chloride, and the like. The catalyst is added in catalytic amounts, i.e., amounts sufficient to etiect reaction between the alkylene oxide and the initiating hydroxylated compound. When the catalyst is alkali metal hydroxide, amounts of from about 0.2 to 1,0 percent by Weight of the alkylene oxide reactant is convenient. When the'cataly'st is a' Lewis acid, such-as boron trifluoride, amounts of from about 0.01 to 1.0 percent by Weight of the alkylene' oxide-freactant'is suitable. The-reaction can be etfecte'd at temperatures of from'EiOf C. to-about 'Cpand advantageously under pressures ranging from about 5 .to .50. pounds per square'inch, gauge. The reaction is preferably carried out under essentially moisture free (anhydrous) conditions to minimize side reaction. The additionof the alkylene'oxide is terminated whenthe calculated quantities thereofhave been introduced-into the systemuv 1 In addition, the above polyisocyanates may be-reacted With'organo polyesters which desirablypossess residual hydroxy'groups. These pol-yester-s'rna'y be branched and! or linear. Branchedechain polyesters-include those? which are of the' cross-linked varietymMoreover, the :te'rmpolyester is meantto. include polyesteramides;:vvhich possess not only recurring ester linkages, but also recurring amide linkages, Such polyesters and'polyesterarnidesare obtained by the reaction of an organic polycarboxylic acidiand an organic-polyol and/ or an organic hydroxyl amine, or from polymerization of an alpha,-omegaehydroxyorganm omega- Illustrative of the polycarboxylic'acids include, erg, ox-alicacid, malonic acid, succinie acid, glutaric acid, adipicacid,' pi-n1elic 'iaCld, suberic: acid, azelai'c acid,

sebacic acid, alkylsuccinic acids, alkenylsuccinic acids, maleic acid, fumaric acid, itaconic acid, citraconic acid, mesaconic acid, muconic acid, alpha-dihydromuconic acid, beta-dihydromuconic acid, diglycolic acid, dilactic acid, thiodiglycolic acid, 4-amyl-2,S-heptadienedioic acid, 3- hexynedioic acid, l,2-cyclhexanedicarboxylic acid, 1,4- cyclohexanedicarboxylic acid, phthalic acid, isophthalic acid, terephthalic acid, tetrahydrophthalic acid, tetrachlorophthalic acid, 1,S-naphthalenedicarboxylic acid, 3- carboxycinnamic acid, l,2-naphthalenedicarboxylic acid, 1,1,5-pentanetricarboxylic acid, 1,2,4hexanetricarboxylic acid, 2-propyl-1,2 ,4pentanetricarboxylic acid, 1,2,3-propanetricarboxylic acid, l,2,4benzenetricarboxylic acid, 1,3,S-benzenetricarboxylic acid, 3-hexene-l,2,3,4 tetracarboxylic acid, 1,2,3,4 benzenetetracarboxylic acid, 1,2,3,5 benzenetetracarboxylic acid, benzenepentacan boxylic acid, benzenehexacarboxylic acid, and the like.

The anhydride and acyl halides of the above polycarboxylic acids may also be employed when such are available. The polyols which may be reacted with the polycarboxylic acids to form the polyesters include, for example, the alkylene oxide adducts or the initiating polyhydroxy substituted organic compounds per se described above. Hydroxy amines which may be empolyed include ethanol amine, 3-aminopropanol, 4-aminopropanol, 5- aminopentanol, 6-aminohexanol, IO-aminodecanol, 6- amino-S-methyl hexanol-l, p-hydroxymethylbenzylarnine, and the like.

The lactone polyesters which contain free hydroxy group(s) and/or carboxyl group(s) represent extremely preferred active hydrogen containing compounds. These lactone polyesters are formed by reacting, at an elevated temperature, for example, at a temperature of from about 50 C. to about 250 C., an admixture containing a lactone and an organic initiator; said lactone being in molar excess with relation to said initiator; said lactone having from six to eight carbon atoms in the lactone ring and at least one hydrogen substituent on the carbon atom which is attached to the oxy group in said ring; said organic initiator having at least one reactive hydrogen substituent preferably of the group of hydroxyl, primary amino, secondary amino, carboxyl, and mixtures thereof, each of said reactive hydrogen substituents being capable of opening the lactone ring whereby said lactone is added to said initiator as a substantially linear group thereto; said initiated lactone polyesters possessing, on the average, at least two of said linear groups, each of said linear groups having a terminal oxy group at one end, a carbonyl group at the other end, and an intermediatae chain of from five to seven carbon atoms which has at least one hydrogen substituent on the carbon atom in said intermediate chain that is attached to said terminal oxy group. The aforesaid polyesters will hereinafter be referred to, in the generic sense, as initiated lactone polyesters which term will also include the various copolymers such as lactone copolyesters, lactone polyester/polycarbonates, lactone polyester/polyethers, lactone polyester/polyether/polycarbon ates, lactone polyester/polyester, etc. These initiated lactone polyesters will contain at least one hydroxyl group and/or at least one carboxyl group depending, of course, on the initiator and reactants employed. Those initiated lactone polyesters which contain at least three alcoholic hydroxyl groups will be referred to as initiated lactone polyester polyols; those with two alcoholic hydroxyl groups will be termed initiated lactone polyester diols. On the other hand, the initiated lactone polyesters which contain at least two carboxyl groups will be referred to as initiated polycarboxy lacone polyesters.

The preparation of the aforesaid hydroxyl-containing and/or carboxyl-containing initiated lactone polyesters can be effected in the absence or presence of an ester interchange catalyst to give initiated lactone polyesters of widely varying and readily controllable molecular weights without forming water of condensation. These lactone polyesters so obtained are characterized by the presence of recurring linear lactone units, that is, carbonylalkyleneoxy the lactone used as starting material can be represented by the general formula:

a cn (tag?) c= in which n' is at least four, for example, from four to six, at least are hydrogen, and the remaining are substituents selected from the group consisting of hydrogen, alkyl, cycloalkyl, alkoxy and single ring aromatic hydrocarbon radicals.

The lactones which are preferred in the preparation of the hydroxyl-containing initiated lactone polyesters are the epsilon-caprolactones having the general formula:

a a a a a l l l a-c-c-iz h-c-cw tilt s wherein at least six of the variables are hydrogen and the remainder may each be one of hydrogen, alkyl, cycloalkyl, alkoxy, or single ring aromatic hydrocarbon radicals, none of the substituents contain more than about twelve carbon atoms, and the total number of carbon atoms in the substituents on the lactone ring does not exceed about twelve.

Among the substituted epsilon-caprolactones considered most suitable are the various monoalkyl epsilon-caprolactones such as the monomethyl-, monoethyl-, monopropyl-, monoisopropyl-, etc. to monododecyl epsilon-caprolactones; dialkyl epsilon-caprolactones in which the two alkyl groups are substituted on the same or different carbon atoms, but not both on the epsilon carbon atom; trialkyl epsilon-caprolactones in which two or three carbon atoms in the lactone ring are substituted, so long as the epsilon carbon atom is not disubstituted; alkoxy epsilon caprolactones such as methoxy and ethoxy epsiloncaprolactones; and cycloalkyl, aryl, and aralkyl epsiloncaprolactones such as cyclohexyl, phenyl and benzyl epsilon-caprolactones.

Lactones having more than six carbon atoms in the ring, e.g., zeta-enantholactone and eta-caprylolactone can be employed as starting material. Mixtures comprising the C to C lactones illustrated previously, with/without, for instance, the alpha, alpha-disubstituted-beta-propiolactones, e.g., alpha, alpha-dimethyl-beta-propiolactone, alpha, alpha dichloromethyl beta propiolactone, etc.; with/without, for instance, oxirane compounds, e.g., ethylene oxide, propylene oxide, etc.; with/without, for instance, a cyclic carbonate, e.g., 4,4-dirnethyl-2,6-dioxacyclohexanone, etc.; are also contempalted.

Among the organic initiators that can be employed to prepare the initiated lactone polyesters include the carboxyl-containing, hydroxyl-containing, and/ or aminocontaining compounds illustrated previously, e.g., those compounds which have at least one reactive hydrogen substituent as determined according to the Zerewitinoif method.

The initiator is believed to open the lactone ring to produce an ester or amide having one or more terminal groups that are capable of opening further lactone rings and thereby adding more and more lactone units to the growing molecule. Thus, for example, the polymerization of epsilon-caprolactone initiated with an amino alcohol is believed to take place primarily as follows:

O l l oR,'NHdoH o H L i 2):; Jo

wherein R (of the initiator and the resulting initiated lactone polyester product) is an organic radical such as an aliphatic, cycloaliphatic, aromatic, or heterocyclic radical, and wherein a=b+c.

The reaction of a carboxyl-containing initiator with epsilon-caprolactone is believed to proceed as follows:

It will be appreciated from the preceding illustrative equations that where a plurality of lactone units are linked together, such linkage is effected by monovalently bonding the oxy (O-) moiety of one unit to the carbonyl moiety of an adjacent unit. The terminal lactone unit will have a terminal hydroxyl or carboxyl end group depending, of course, on the initiator employed.

The preparation of the initiated lactone polyester can be carried out in the absence of a catalyst though it is preferred to effect the reaction in the presence of an ester exchange catalyst. The organic titanium compounds that are especially suitable as catalysts include the tetraalkyl titanates such as tetraisopropyl titanate and tetrabutyl titanate. Additional preferred catalysts include, by way of further examples, the stannous diacylates and stannic tetraacylates such as stannous dioctanoate and stannic tetraoctanoate. The tin compounds, the organic salts of lead and the organic salts of manganese which are described in US. 2,890,208 as well as the metal chelates and metal acylates disclosed in US. 2,878,236 also represent further desirable catalysts which can be employed. The disclosures of the aforesaid patents are incorporated by reference into this specification.

The catalysts are employed in catalytically significant concentration. In general, a catalyst concentration in the range of from about 0.0001 and lower, to about 3, and higher, weight percent, based on the weight of total monomeric feed, is suitable. The lactone polymerization reaction is conducted at an elevated temperature. In general, a temperature in the range of from about 50 C., and lower, to about 250 C. is suitable; a range from about C. to about 200 C. is preferred. The reaction time can vary from several minutes to several days depending upon the variables illustrated immediately above. By employing a catalyst, especially the more preferred catalysts, a feasible reaction period would be about a few minutes to about 10 hours, and longer.

The polymerization reaction preferably is initiated in the liquid phase. It is desirable to effect the polymerization reaction under an inert atmosphere, e.g., nitrogen.

The preparation of the lactone polyesters via the preceding illustrative methods has the advantage of permitting accurate control over the average molecular weight of the lactone polyester products and further of promoting the formation of a substantially homogenous lactone polyester in which the molecular weights of the individual molecules are reasonably close to the average molecular weight, that is, a narrow molecular weight distribution is obtained. This control is accomplished by preselecting the molar proportions of lactone and initia tor in a manner that will readily be appreciated by those skilled in the art. Thus, for example, if it is desired to form a lactone polyester in which the average molecular weight is approximately fifteen times the molecular weight of the initial lactone, the molar proportions of lactone and initiator utilized in the polymerization reaction are fixed at approximately 15:1 inasmuch as it is to be expected that on the average there will be added to each molecule of initiator approximately fifteen lactone molecules.

The initiated lactone polyesters which are contemplated have average molecular weights as low as 300 to as high as about 7000, and even higher still to about 9000. With vinyl polymers containing a plurality of active hydrogen substituents, e.g., hydroxyl, amino, etc. as initiators, the average molecular weight of the initiated lactone olyesters can easily go as high as 14,000, and higher. Generally, however, the average molecular Weight of the initiated lactone polyester is from about 300 to about 9000, preferably from 600 to about 5000.

Also included within the term and scope of the initiated lactone polyesters are those in which the linear lactone units need not necessarily be connected directly to one another. This is readily accomplished, for example, by reacting lactone(s) with combinations of initiators such as dibasic acid(s) plus glycol(s), diamine(s) or amino alcohol(s) such as those exemplified previously.

This reaction can be eifected at an elevated temperature, e.g., about 100 C. to about 200 C., with all the reactants present, or the reaction of the dibasic acid with the glycol, diamine, or amino alcohol can be accomplished first, and then the resulting amino-, hydroxyl-, or carboxyl-containing products (depending on the reactants and the concentration of same) can be reacted with the lactone to yield hydroxyl'terminated and/ or carboxyl-terminated initiated lactone olyesters. Moreover, as also indicated previously, the term and the scope of the hydroxyland/or carboxyl-containing initiated lactone polyesters includes the oxyalkylene-carboxyalkylcues such as described in US. Patent No. 2,962,524 which are incorporated by reference into this disclosure. In addition, the term and scope of the hydroxyl-containing initiated lactone polyesters also includes the reaction of an admixture comprising a C C lactone(s), a cyclic carbonate(s), and an initiator having at least one group, preferably at least two groups, of the class of hydroxyl,

primary amino, or secondary amino, or mixtures thereof, under the operative conditions discussed above. Exemplary cyclic carbonates include 4,4-dimethyl-2,6-dioxacyclohexanone, 4,4 dichloromethyl-Z,6-dioxacyclohexanone, 4,4 dicyanomethyl 2,6 dioxacyclohexanone, 4,4- diethyl 2,6 dioxacyclohexanone, 4,4 dimethoxymethyl 2,6 dioxacyclohexanone; and the like. Consequently, where a mixture of linear lactone units (i.e.,

units which are properly termed carbonylalkyleneoxy) and linear carbonate units (i.e.,

units which can be termed carbonyloxyalkyleneoxy) are contained in the polymer chain or backbone, the carbonyl moiety of one linear unit will be monovalently bonded to the oxy moiety of a second linear unit. The oxy moiety of a terminal linear unit will be bonded to a hydrogen substituent to thus form a hydroxyl end group. Moreover, the point of attachment of the initator and a linear unit (lactone or carbonate) will be between the carbonyl moiety of said unit and the functional group (hydroxyl or amino) of said initiator minus the active hydrogen of said group.

Additional initiated lactone polyesters include those which contain at least about 50 mol per cent of carbonylpentamethyleneoxy units therein and which possess an average molecular weight of from about 500 to about 5000, particularly from about 600 to about 4000. The remaining portion of the molecule can be comprised of, in addition to the initiator, essentially linear units derived from a cyclic carbonate especially those illustrated previously; an oxirane compound especially ethylene oxide, propylene oxide, and/or butylene oxide; a monoand/or polyalkyl-substituted epsilon-caprolactone especially the monoand/or polymethyl and/or ethyl-substituted epsilon-caprolactones; and/or an alpha, alpha-disubstitutedbeta-propiolactone especially those exemplified previously. The so-called initiated lactone homopolyesters derived from reacting epsilon-caprolaetone with an initiator are likewise included within the preferred lactone polyesters. The initiated lactone polyester polyols, and in particular, the substantially linear initiated lactone polyester diols, are exceptionally preferred.

Reaction between the polyisocyanates and the active hydrogen-containing organic compounds may be effected at temperatures ranging from C. to 250 C. preferably from 25 C. to 150 C. The reaction is effected by intermixture of the components of the reaction, followed by heating of the mixture, if necessary.

The above reaction between the polyisocyanate of this invention and the polyols and/or polyesters described above may be employed to produce Cross-linked infusible solid resins, substantially linear fusible (or heat softenable) solid resins, to short chain length viscous liquids. Such is achieved by proper selection of the polyol reactant, the degree of the polymerization, the ratio of reactants to each other (polyol vs. diisocyanate), and the like considerations.

A particularly useful polymer is a polyurethane-polyurea obtained by the reaction of a diisocyanate encompassed by Formula II and the initiated lactone polyester polyols, described above, to form a prepolymer having a molecular weight not in excess of about 10,000, preferably from about 400 to about 5,000. This prepolymer may be isocyanate end-blocked or hydroxyl end-blocked depending on which reactant is employed in stoichiometric excess. If hydroxyl end-blocked, the prepolymer is reacted with additional diisocyanate to form an isocyanate end-blocked product.

With addition of further diisocyanate, or to the already isocyanate end-blocked polymer, may be added a poly-nitrogen compound possessing at least one hydrogen bonded to each nitrogen atom. illustrative poly-nitrogen compounds are, e.g., hydrazine, hydrazine hydrate, symmetn'cal-dimethyl substituted hydrazine, symmetricaldiphenyl substituted hydrazine, alkylene diamines such as ethylene diamine, trimethylene diamine, tetramethylene diamine, petamethylene diamine, hexamethylene diamine, and the like, cycloaliphatic diamines such as 2,5 or 2,6-bis-(amiuomethyl) norbornane, 2 aminOmethyl-S (or 6) (Z-aminoethyl) norbornane, 1,4-bis(aminomeththyl) cyclohexane, 1,4-diamino-cyclobutane, and the like.

On reaction of the poly-nitrogen compound with the poly-isocyanate end-blocked polyester, the polyester is chain extended to form a film and fiber-forming elastomeric polymer having a molecular weight typically in eX- cess of 5,000, preferably in excess of 10,000. These polymers can be dissolved in such active solvents as dimethylformamide, dimethylacetamide, tetrahydrofuran, dioxane, and the like to allow extrusion, knife coating, casting, or roller coating to form films or wet spun into a non-solvent (e.g., water) to form fibers and filaments.

The urethane reaction can be induced by use of catalysts such as the polyurethane foam catalyst described below.

The above polyisocyanates can be employed to make foams from the aforementioned polyol reactants. The molecular weight and the hydroxyl number of the polyol when used for reaction with a polyisocyanate to form polyurethane foams will determine whether the resulting foam product is flexible or rigid. For example, the above polyols which possess a hydroxyl number of from about 200 to about 1000 are typically employed in rigid foam formulations, while these polyols having a hydroxyl number of from about 20 to about 150 or more are usually employed in flexible foam formulations. Such limits are not intended to be restrictive and are merely illustrative of the potential selectivity of the above polyol co-reactants. Other modifications of possible polyol combinations Will be readily apparent to those having ordinary skill in the art.

The hydroxyl number, as used hereinabove, is defined by the equation:

molecular Wei gig wherein OH is the hydroxyl number of the polyol, represents functionality (i.e., average number of hydroxyl groups per molecule of polyol), and molecular Weight is the average molecular weight of the polyol.

Methods for making the aforementioned polyurethane flexible foams are well documented in the art.

When preparing the foamed products, either the quasiprepolymer technique or the one-shot technique can be employed. Both techniques are known in the art.

Foaming can be accompiished by employing a small amount of water in the reaction mixture (for example, from about 0.5 to 5 weight percent of water, based on total weight of the reaction mixture), or through the use of blowing agents which are vaporized by the exotherm of the isocyanate-hydroxyl reaction or by a combination of the two methods. All of these methods are known in the art. The preferred blowing agents are certain halogen-substituted aliphatic hydrocarbons which have boiling points between about 40 C. and C., and which vaporize at or below the temperature of the foaming mass. These blowing agents include, for example, trichloromonofiuoromethane, dichlorodifluoromethane, dichloromonofluoromethane, dichloromethane, trichloromethane, bromotrifiuoromethane, chlorodifluoromethane, chloromethane, 1,l-dichloro-l-fluoroethane, 1,1-clifiuoro- 1,2,2-trichloroethane, chloropentafluoroethane, 1,1,1-trifiuoro-Z-chloroethane, l-chloro-l-fiuoroethane, 1,1,1-trichloro-2,2,Z-trifiuoroethane, 1,1,Z-trichloro-1,2,2-trifluoro ethane, l-chloro-Z-fluoroethane, Z-chloro-l,l,l,2,3,3,4, nonafiuorobutane, hexafiuorocyclobutane, and octafiuorocyclobutane.

Other useful blowing agents include low-boiling hydrocarbons such as butane, pentane, hexane, cyclohexane, and the like. Many other compounds easily volatilized by the exotherm of the isocyanate-hydroxyl reaction can also be employed. A further class of blowing agents includes thermally-unstable compounds which liberate gases upon heating, such as N,N'-dimethyl-N,N-dinitrosoterephthalamide.

The amount of blowing agent used will vary with the density desired in the foamed product. In general, it may be stated that for 100 grams of reaction mixture containing an average NCO/OH ratio of about 1:1, about 0.005 to 0.3 mole of gas is used to provide foams having densities ranging from 30 to 0.8 pounds per cubic foot, respectively.

A conventional catalyst can be employed in the reaction mixture for accelerating the isocyanate-hydroxyl reaction. Such catalysts include a wide variety of compounds such as, for example, (a) tertiary amines such as trimethylamine, 1,2,4-trimethylpiperazine, 1,4-dimethylpiperazine, N-methylmorpholine, N-ethylmorpholine, N,N- dimethylbenzylamine, bis (dimethylaminomethyl) amine, N,N-dimethylethanolamine, N,N,N,N-tetramethyll ,3-- butanediamine, triethanolamine, l,4-diazabicyclo[2.2.2] octane, and the like; (b) tertiary phosphines such as trialkylphosphines, dialkylbenzylphosphines, and the like; (c) strong bases such as alkali and alkaline earth metal hydroxides, alkoxides, and phenoxides; (d) acidic metal salts of strong acids such as ferric chloride, stannic c1110- ride, stannous chloride, antimony trichloride, bismuth nitrate and chloride, and the like; (e) chelates of various metatls such as those which can be obtained from acetylacetone, benzoylacetone, trifiuoroacetylacetone, ethyl acetoacetate, salicylaldehyde, cyclopentanone 2 carboxylate, acetylacetoneimine, bis-acetylacetonealkylenediamines, salicylaldehydeimine, and the like; with various metals such as Be, Mg, Zn, Cd, Pb, Ti, Zr, Sn, Sb, As, Bi, Cr, Mo, Mn, Fe, Co, Ni, or such ions as MoOf and the like; (f) alcoholates and phenolates of various metals such as Ti(OR),,, Sn(OR) Sn(OR) Al(OR) and the like, wherein R is alkyl or aryl, and the reaction products of these alcoholates with carboxylic acids, beta-diketones and 2(N,N-dialkylamino) alkanols, such as the well known chelates of titanium obtained by said or equivalent procedures; (g) salts of organic acids with a variety of metals such as alkali metals, alkaline earth metals, Al, Sn, Pb, Sb, Mn, Co, Ni and Cu, including, for example, sodium acetate, potassium laurate, calcium hexanoate, stannous acetate, stannous octoate, stannous-2-ethylhexanoate, stannous oleate, lead octoate, metallic driers such as manganese and cobalt naphthenate, and the like; (h) organometallic derivatives of tetravalent tin, trivalent and pentavalent As, Sb and Bi, and metal carbonyls of iron and cobalt. Among the organotin compounds that deserve particular mention are dialkyltin salts of carboxylic acids, e.g., dibutyltin diacetate, dibutyltin dilaurate, dibutyltin maleate, dilauryltin diacetate, dioctyltin diacetate, dibutyltin-bis[4 (N,N' dimethylamino)benzoate], dibutyltinbis[6-(N-tnethylamino)caproate], and the like. Similarly, there can be used a trialkyltin dichloride. Examples of these compounds include trimethyltin hydroxide, tributyltin hydroxide, trioctyltin hydroxide, dibutyltin oxide, dioctyltin oxide, dilauryltin oxide, dibutyltin-bis(isopropoxide), dibutyltin-bis(2 diethylaminopentylate), dibutyltin dichloride, dioctyltin dichloride, and the like.

The tertiary amines may be used as primary catalysts for accelerating the active hydrogen-isocyanate reaction or as secondary catalysts in combination with metal catalysts. The catalysts are employed in small amounts, for

example from about 0.001 percent to about 5 percent, based on the weight of the reaction mixture.

It is also desirable to employ small amounts, e.g., about 0.001 percent to 5.0 percent by weight, based on the total reaction mixture, of an emulsifying agent such as siloxaneoxyalkylene block copolymer having from about 10 to percent by weight of siloxane polymer and from to 20 percent by weight of alkylene oxide polymer, such as the block copolymers described in U.S. Patents Nos. 2,- 834,748 and 2,917,480.

Another class of useful emulsifiers are the non-hydrolyzable polysiloxane-polyoxyalkylene block copolymers. This class of compounds differs from the abovementioned polysiloxane-polyoxyalkylene block copolymers in that the polysiloxane moiety is bonded to the polyoxyalkylene moiety through direct carbon to silicon bonds, rather than through carbon to oxygen to silicon bonds. The copolymers generally contain from 5 to weight percent, and preferably from 5 to 50 weight percent of polysiloxane polymer with the remainder being polyoxyalkylene polymer. The copolymers can be prepared, for example, by heating a mixture of (a) a polysiloxane polymer containing a silicon-bonded, halogen substituted monovalent hydrocarbon group, and (b) an alkali metal salt of a polyoxalkylene polymer, to a temperature sufficient to cause the polysiloxane polymer and the salt to react to form the block copolymer. Although the use of an emulsifier is desirable to influence the type of foam structure that is formed the foam products of the invention can be prepared without emulsifiers in some cases.

Further polyurethanes which deserve mention here are those which are formed by the reactions of the aforementioned diisocyanates, encompassed by Formula II, with alkyd resins such as the polyester reaction product of unsaturated or saturated fatty acids (such as linoleic and stearic acid) with the hydroxyl containing polyester reaction product of maleic or phthalic acid and glycerol to make useful coating resins. The alkyd resins may also be formed by the cooking of vegetable or fish oils such as linseed oil, soybean oil, cottonseed oil, codliver oil, tung oil, and the like, with maleic acid, or its acid chloride and esters. The resulting alkyd reaction product is then intermixed and reacted with the aforementioned diisocyanate to produce a polyurethane-based varnish.

Illustrative of polyesters employing the compounds of Formula II are those which are formed from the esterification reaction between the acid, ester or acid chloride substituted norbornanes encompassed by Formula II and the aforementioned polyols. The reaction may be effected in the presence of an acid or alkaline catalyst of the conventional type. These polyesters range in properties from hard brittle solids to very flexible or soft plasticizing materials. For example, polyesters formed from the reaction of 2-carboxymethyl-5 (or 6)-carboxynorbornane and 2,5 (or 6)-bis(hydroxymethyl)norbornane are excellent coating resins which are very flexible but relatively high melting films. This polyester can be.,melt extruded in the form of filaments and fibers. A most desirable polyester is one obtained from the aforementioned dicarboxylic acid and Bisphenol A (2,2 bis(4 hydroxyphenyl)propane). This polyester is exceptionally high melting and forms very useful films and fibers. An additional polyester which possesses very useful properties is that formed by the reaction of the aforementioned dicarboxylic acid and 1,4- bis(hydroxymethyl)cyclohexane. This polyester possesses most suitable fiber-forming and film-forming qualities.

Another class of polyesters which can be manufactured utilizing diol reactants embodied by Formula II above include the reaction product of terephthalic acid, its acid chlorides and diesters and the aforementioned diol such as 2,5 (or 6)-bis(hydroxymethyl)norbornane, 2-hydroxymethyl-5 (or 6)-hydroxyethyl norbornane, and the like. The latter norbornane diol is much preferred providing, after reaction, most desirable fiber-forming and filmforming polyesters. 

